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VK4105G SERIES

GAS CONTROLS FOR COMBINED VALVE AND IGNITION MODULATING SYSTEM


PRODUCT HANDBOOK

APPLICATION

Subject to change without notice. Printed in the Netherlands.

The VK4105G and S4565.M, Combined Valve and Ignition


modulating system (CVI--m), have specially been developed
for application in gas fired appliances with direct burner
ignition that require electric modulating control of the gas input
like instantaneous hot water combi boilers and air heating
appliances.
For this system, the VK4105G series gas control has been
designed to have a S4565.M series ignition control attached
directly onto the valve.
The combined system then provides programmed safe light
up, flame supervision, regulation, modulation or Hi--Lo control
of the gas flow to the main burner of the appliance.

General

Contents
Page

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Gas control
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Performance characteristics . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjustments and checkout . . . . . . . . . . . . . . . . . . . . . . . . 13
Construction and working principles . . . . . . . . . . . . . . . . . 14

Various
Quality assurance statement . . . . . . . . . . . . . . . . . . . . . . .
Standards and approvals . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordering information . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement parts and accessories . . . . . . . . . . . . . . . .

15
16
17
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EN2R--9025 0108R6--NE

DESCRIPTION
Valves
The Combined Valve and Ignition modulating (CVI--m) system
controls and performs all the functions required for safe
ignition, flame supervision and for safely regulating the gas
flow to the main burner.
The construction of the VK4105G valve is optimized and
dedicated to function in combination with the S4565.M ignition
control.

The CVI--m system comprises a modulating gas control with


on/off regulating and modulating function and an ignition
control with integrated power supply for the electric
modulating operator.
The power supply for the modulating current is generated by
the ignition control.
The CVI--m gas control comprises a standard body to which a
range of features can be factory included to give various
functional options.
These functional options include: servo pressure regulation,
modulating control to fulfil a range of control applications.
The CVI--m gas control has a first direct on/off operator for
opening the safety valve of class B according to EN 161 and
a second electric on/off servo operator for control of the main
valve of class J according to EN 161 (for explanation class J,
see chapter Standards and approvals page 16).
The second electric operator also includes the modulation
function. The minimum gas flow can be set by means of an
adjustable throttle.
The pressure regulator is in accordance with class B
requirements of EN 88.
The CVI--m can handle natural gas and LP gas.

General
All measurements are carried out under standard conditions
listed below unless otherwise is indicated.
Standard conditions
Pinlet 25 mbar nominal pressure, dry air of 20 _C
Pambient 1013 mbar
Tambient 20 _C
Outlet orifice 4.3 mm
Flow indication in m3/h
Recording of outlet pressure with a transducer connected
to a 1/2 pipe with a length of 10 times the diameter with a
short hose at 5times the diameter.
Nominal voltage
90_ tilted, i.e. the position when the operators are lying
horizontal.

EN2R--9025 0108R6--NE

FEATURES
Gas connection options
Inlet 18.6 mm and outlet 18.6 mm are straight through
and can receive flanges.
Internal thread (ISO 7--1):
3/ inlet and 3/ end outlet; body length 115 mm.
8
8
1/ inlet and 1/ end outlet; body length 115 mm.
2
2
1/ NPT inlet and flanged end outlet;

2
body length 115 mm.
External thread :
1/ inlet and 1/ end outlet; body length 135 mm
2
2
1/ inlet and standard flanged end outlet;
2
body length 120 mm
3/ inlet and 3/ end outlet; body length 135 mm
4
4
3/ inlet and standard flanged end outlet;
4
body length 120 mm
3/ inlet and standard flanged side outlet;
4
body length 120 mm
The side outlet can only be connected to a flanged burner
manifold.
Pressure feedback fittings for 4 or 6 mm silicon tube can
be mounted.

General
All burner control safety functions concentrated in one
reliable and optimized system.
Specially designed to provide the optimum system solution
in gas appliances with a DBI to light the main burner.
VK4105G gas control incorporates time proven design
concepts assuring reliability.
ON/OFF control of main burner by electric operator and
electric servo operator directly energized from ignition
control.
Easy assembly of ignition control on gas control by
plugging it on from the top.
Mounting orientation must be 90_ in any direction from the
electric on/off operator upright position.
Incorporated electric modulating or Hi--Lo regulation.
Throttle for minimum flow setting
Gas control
Closing force: B + J
Servo pressure regulator provides stable outlet pressure.
Pressure feedback on maximum setting ensures constant
burner pressure in relation to combustion chamber
pressure.
All adjustments are accessible from the top.
9 mm diameter pressure taps on top face for checking inlet
and outlet pressure
Two mounting holes for thread forming screws are at the
bottom of the gas control for rigid attachment to the
appliance.

Electrical connection
The appropriate ignition control can be connected to the
valve by plugging it on.

EN2R--9025 0108R6--NE

DIMENSIONAL DRAWING STANDARD CONNECTION


Mechanical minimum adjustment
62

Pressure tap (2)

13.4
OUT

Hole 2.6 to connect


ignition control

MIN

24.9

1
V1

87.5
84.5

V2

Maximum pressure regulator

Earth terminal
84.5
115
Molex 1.1 square pin header
(mating connectors 3001 series)

Pressure feedback connection


Outlet

Inlet
113

91
24

93.5

36.7

24
36.7
24

24

Side outlet
64.7
30
Mounting hole (2) for
tapping screws 3.9
DIN 7990

M5 x 0.8(3)
6 min full thread

12

O-- ring size


15.55 x 2.62

36.7

29.4
8

105

8 x 3.3 high
2.8

24.1
9.1

24.3
68.3

12
29

EN2R--9025 0108R6--NE

DIMENSIONAL DRAWING EXTERNAL THREAD CONNECTION

94.8
Hole 2.6 to connect
ignition control

61.6

13.4
OUT
MIN

V1

24.9
53.2

V2

84.5

Earth terminal
84.5
115

Molex 1.1 square pin header


(mating connecters 3001 series
113

Inlet
G 1/2 or
G 3/4

91

Pressure feedback
connection
Outlet
G 1/2 or
G 3/4

80

20.7

36.7

36.7

30
30
Mounting hole (2) for tapping
screws 3.9 according DIN 7970
15

64.7

300.5
15

29.4
80.5

15 ref

1050.7
135

EN2R--9025 0108R6--NE

SPECIFICATIONS
Mounting position
90_ tilted (i.e. with coils horizontal) in any direction from the
upright, deviation 5_ max.

Models
See model number chart on page 17
Main gas connection
Standard see table 2. page 6
Optional see table 3. page 6
Side outlet can be fitted direct to a flanged burner manifold.
Inlet and outlet with 3/8 or 1/2 ISO 7--1 internal pipe thread
and straight or elbow flanges with 3/8 or 1/2 ISO 7--1 internal
pipe thread are according to the torsion and bending stress of
EN126 group 2
Connections with G 1/2 or G 3/4 external thread fitted with
nuts according to ISO 228--1 in combination with applicable
sealing(s) withstand the torsion and bending stress of
EN 126 group 1

NOTE: Upright position is not applicable


Mounting holes
Two mounting holes for thread forming M4 screws are located
on the bottom of the gas control.
For versions with external thread there are two additional
mounting holes for thread forming screws at the inlet side of
the gas control.
The four holes at inlet and outlet for mounting a flange on the
gas control are provided with M4 thread with a minimum of 6
mm full thread.
In case of side outlet the three holes for mounting the flange
are provided with M5 thread with a minimum of 6 mm full
thread.

Ambient temperature
--15 ... 60 _C
Humidity
95% RH max. at 40 _C

Table 1. Power consumption (W)


Power consumption 1st + 2nd operator

Storage
-- 30 ... 70 _C
Pressure feedback connection
The servo pressure regulator has an M5 thread connection for
pressure feedback on maximum pressure setting.

Nominal voltage to
S4565.M 230 V, 50 Hz

110% nominal voltage to


S4565.M 253 V, 50 Hz

VA

VA

7.2

8.7

7.9

9.6

Table 2. Standard valve connection

Dimensions
See dimensional drawing page 4 and page 5
Minimum capacity
The minimum rate is adjustable with a throttling screw from
0.2 m3/h air up to 0.92 m3/h air at P = 17 mbar
Outlet pressure range
1.5 ... 32 mbar
Minimum rate range
1.5 ... 7 mbar
Maximum inlet pressure
60 mbar
Modulation characteristics
In fig 1. and fig 2. the modulation performance of the CVI--m
system is reflected at 20 mbar and 37 mbar.
Closing time
< 1 second

Inlet

End outlet

Side outlet

Body length
(mm)

Flanged

Flanged

----

105

Flanged

----

Flanged

105

Internal 3/8
ISO 7--1

----

Flanged

115

Internal 1/2
ISO 7--1

----

Flanged

115

Internal 1/2
ISO 7--1

Internal 1/2
ISO 7--1

----

115

Internal 1/2
NPT

Internal 1/2
NPT

----

115

Table 3. External valve connection (optional)

Electrical data
Power consumption: see table 1.
Max modulation current at nominal voltage: 30 mA
Valve classification
1st valve: class B, 50 mbar backpressure
2nd valve: class J, 0 mbar backpressure
Maximum operating pressure
The Pmax = 60 mbar indication on the housing of the gas
control is the maximum pressure at which it functions safely.

Inlet

End outlet

Side outlet

Body length
(mm)

G 1/2

G 1/2

----

135

1/
2

Flanged

----

120

3/
4

3/
4

----

135

G 3/4

Flanged

----

120

G 3/4

----

Flanged

120

EN2R--9025 0108R6--NE

17

15

13

Poutlet (mbar)

11

1
0

10

20

30

40

50

60

70

80

PWM (%*)
downward nominal curce
upward nominal curve
* HI--Lo versions:
Hi--Lo contact open corresponds to 0% PWM
Hi--Lo contact closed corresponds to 100% PWM
Fig. 1. Tolerance graph modulating performance at 20 mbar inlet pressure,
(VK4105G + S4565.M)

4.3 mm outlet restriction

37
35
33
31
29

Poutlet (mbar)

27
25
23
21
19
17
15
13
11
9
7
5
3
0

10

20

30

40

50

60

70

80

90

100

PWM (%*)

downward nominal curce


upward nominal curve
* HI--Lo versions:
Hi--Lo contact open corresponds to 0% PWM
Hi--Lo contact closed corresponds to 100% PWM

Fig. 2. Tolerance graph modulating performance at 37 mbar inlet pressure,


(VK4105G + S4565.M)

2.8 mm outlet restriction

EN2R--9025 0108R6--NE

PERFORMANCE CHARACTERISTICS
Oscillation
The difference between maximum and minimum outlet
pressure must be equal or less than 0.5 mbar.
Test conditions:
-- maximum inlet pressure in accordance with regulator
range.
-- outlet orifice 2.8 dia (this means 0.3 m3/h air at 2 mbar
outlet pressure)
-- recording of outlet pressure with a transducer connected
to a 1/2 pipe with a length of 10 d. with a short hose
at 5 d.
-- attenuation X--Y recorder must be switched on zero.
--other pressure gauges or flow meters must be
disconnected.
-- Ambient temperature 20 _C

Maximum allowable leakage


Each gas control is factory tested to meet the following
leakage requirements:
outerwall: 50 cm3/h at test pressure of 150 mbar.
safety valve: 40 cm3/h at test pressure of 6 and 150 mbar.
main valve (plus operator inlet valve): 40 cm3/h at test
pressure of 6 and 150 mbar.
Outlet pressure adjustment range capability
Natural/LP gas: 1.5 ... 32 mbar
Minimum capacity
The minimum rate is adjustable with a throttling screw
from < 0.2 m3/h air up to 0.92 m3/h air at P = 17 mbar
High pressure test
In the OFF condition, the gas control will withstand 3 bar (air)
inlet pressure without damage. Attempts to operate the gas
control, while in this fault condition will not damage it.

Tap sensitivity of maximum outlet pressure set point


For all gases the maximum deviation may be 1 mbar or 10%
whichever is the greatest.

Operable voltage range


The gas control will function satisfactory between 85% and
110% of the rated voltage on S4565.M.
Table 4. Operable voltage range
Rated voltage

Operable voltage

230 V, 50 Hz

196 ... 253 V

Repeatability of maximum outlet pressure set point


For all gases the maximum deviation from set point is: 0.5
mbar or 3% of the set point value, whichever is the
greatest.
Total set point shift
Table 5. Total set point shift

Valve closing characteristics


The VK4105G will close within 1 second from operator
de--energization, (at an inlet pressure of 22.5 mbar and
minimal 2.5 mbar pressure drop).
Main valve opening characteristics (measured with gas)
Under conditions where the supply pressure is at least 2.5
mbar above the outlet pressure setting, the dead time shall be
0.5 s maximum.
The outlet pressure will reach 80% of the rated flow within 1
second from start of flow.
Full outlet pressure will be reached within 5 seconds.

Pressure
range (mbar)

Tolerance

1.5 ... 32

6% of the set point value or 1 mbar


whichever is the greatest

Design life
500.000 cycles for safety and main valve operator.
Cycle frequency maximum100 cycles /hour.

EN2R--9025 0108R6--NE

INSTALLATION
Gas controls for flange connection

IMPORTANT
Take care that installer is a trained experienced
service person.
Turn off gas supply before starting installation.
Disconnect power supply to prevent electrical shock
and/or equipment damage.
Do not remove seals over inlet and outlet until the
device is ready to be installed.
Take care that dirt cannot enter the gas control
during handling.

Insert O--ring in the groove of each flange.


If necessary grease O--ring slightly to keep it in place.
Mount gas control between flanges using the four screws
for each flange.

Gas controls with external thread connection

IMPORTANT
Fastening torque flat sealing ring only applicable for
type Klingersil C4324
Olives for this application are not supplied by
Honeywell
Torque of olive applications may differ depending on
olive dimensions.

Mounting position
90_ tilted (i.e. with coils horizontal) in any direction from the
upright, deviation 5_ max.

NOTE: Upright position is not applicable

Main gas connection

Gas controls with internal thread


Take care that dirt cannot enter the gas control during
handling.
Use a sound taper fitting with thread according to ISO 7--1
or a piece of new, properly reamed pipe, free from swarf.
Do not thread or tighten the pipe or pipe fitting too far (see
table below). Otherwise distortion and malfunction could
result.
Pipe size (inch)

Max. length of pipe thread (mm)

3/
8

14

1/
2

18.6

With 1/2 nut and flat sealing ring for pipe 14 mm (see fig 4.)
Nut: order number: . . . . . . . . . . . . . . . . 45.900.447--005
Flat sealing ring according to DIN 3535--6 with size
18 x 12 x 1.5 mm
order number . . . . . . . . . . . . . . . . . . . . . 45.900.447--007
Fastening torque: maximum 40 Nm
minimum 25 Nm
Pipe end construction: see fig.: 7.
With 1/2 nut and flat sealing ring for pipe 15 mm (see fig 4.)
Nut: order number: . . . . . . . . . . . . . . . . 45.900.447--004
Flat sealing ring according to DIN 3535--6 with size
18 x 12 x 1.5 mm
order number . . . . . . . . . . . . . . . . . . . . . 45.900.447--007
Fastening torque: maximum 40 Nm
minimum 25 Nm
Pipe end construction: see fig.: 8.

Apply a moderate amount of good quality thread


compound to the pipe or fitting only, leaving the two end
threads bare. PTFE tape may be used as an alternative.
Tighten gas control using the right open end wrench.
See fig. 3.

Fig. 4. External thread connection with nut and flat


sealing ring
3

With 3/4 nut and olive (see fig. 5.)


Pipe diameter: 15 mm
Nut: order number: . . . . . . . . . . . . . . . . 45.900.447--003
Fastening torque: maximum 50 Nm
minimum 30 Nm
Pipe end construction: square off end of tubing and
remove burrs.

Fig. 3.
Ensure the gas flows in the same direction as the arrow on
the bottom of the gas control.

EN2R--9025 0108R6--NE

With 3/4 nut and flat sealing ring for pipe 18 mm (see fig 4.)
Nut: order number: . . . . . . . . . . . . . . . . 45.900.447--002
Flat sealing ring according to DIN 3535--6 with size
24 x 16 x 1.5 mm
order number . . . . . . . . . . . . . . . . . . . . . 45.900.447--006
Fastening torque: maximum 50 Nm
minimum 30 Nm
Pipe end construction: see fig.: 11.
18 +0.2
--0.2

14

1
Fig. 7. Pipe (dia 14 mm) for flat sealing ring connection
Fig. 5. External thread connection with nut and olive
4

18 +0.2
--0.2

15

With 3/4 nut and O- ring (see fig 6.)


Pipe diameter: 15 mm
Nut: order number: . . . . . . . . . . . . . . . . 45.900.447--003
O--ring size: 14.3 x 2.4 mm
order number . . . . . . . . . . . . . . . . . . . . . 45.900.447--001
Fastening torque: maximum 50 Nm
minimum 10 Nm
Pipe end construction: see fig.: 9.

1
Fig. 8. Pipe (dia 15 mm) for flat sealing ring connection
23.40.15
15 +0.10
--0.05

15
1.50.1

7.50.2
Fig. 9. Pipe end for O--ring connection

23.4 +0.2
--0.2

15

1
Fig. 10. Pipe (dia 15 mm) for flat sealing ring connection

23.4 +0.2
--0.2

18
Fig. 6. External thread connection with nut and
O--ring
5

1
Fig. 11. Pipe (dia 18 mm) for flat sealing ring connection

With 3/4 nut and flat sealing ring for pipe 15 mm (see fig 4.)

Nut: order number: . . . . . . . . . . . . . . . . 45.900.447--003


Flat sealing ring according to DIN 3535--6 with size
24 x 16 x 1.5 mm:
order number . . . . . . . . . . . . . . . . . . . . . 45.900.447--006
Fastening torque: maximum 50 Nm
minimum 30 Nm
Pipe end construction: see fig.: 10.

Pressure feedback connection

WARNING
To avoid decreasing of performance of pressure
regulator by pinching off the pressure feedback tubing,
it is recommended to use a tube material which will not
kink.

10

EN2R--9025 0108R6--NE

Perform gas leak test

Pilot gas connection (if applicable)


Square off the end of tubing and remove burrs.
Slip compression fitting over tubing.
Insert tubing into gas control housing until it bottoms, slide
fitting into place and turn finger tight.
Use a wrench to tighten fitting about 11/2 turn beyond
finger tight to shear of the olive.
Do not use jointing compound.
Connect other end of tubing to pilot burner according to the
manufacturers instructions.

WARNING
FIRE OR EXPLOSION HAZARD CAN CAUSE
PROPERTY DAMAGE, SEVERE INJURY OR
DEADTH
Check for gas leaks with a rich soap and water
solution any time work is done on a gas control.
Gas leak test
Paint all pipe connections upstream of the gas control with
a rich soap and water solution. Bubbles indicate a gas
leak.
If a gas leak is detected, tighten the pipe connection.
Stand clear while lighting the main burner to prevent injury
caused from hidden gas leaks, which could cause flasback
in the appliance vestibule. Light the main burner.
With the main burner in operation, paint all pipe joints
(including adapters) and gas control inlet and outlet with
with a rich soap and water solution an approved leak
detection fluid.
If another gas leak is detected, tighten adapter screws,
joints and pipe connections.
Replace the part if gas leak can not be stopped.

CAUTION
Do not bend tubing at gas control after compression
fitting has been tightened, as this may result in gas
leakage at the connection.

CAUTION
Keep soap and water solution away from electrical
connections.

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EN2R--9025 0108R6--NE

ELECTRICAL CONNECTION
Electrical connection details
See Product Handbook EN2R--9028

IMPORTANT
Disconnect power supply to prevent electrical shock
and/or equipment damage.
Wiring must be in accordance with local regulations.
The appliance manufacturers instructions should
always be followed when provided. If such
instructions are not provided see the connection
diagrams for typical systems.
Before installing or replacing any control check that
type number is correct for the application.
Ensure combustion chamber is free of gas before
start up.
Conduct a thorough check out when installation is
completed.

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EN2R--9025 0108R6--NE

ADJUSTMENTS, FINAL CHECKOUT AND MAINTENANCE


Adjustment

Setting of mechanical minimum rate (see page 4)


Disconnect PWM input signal.
Make sure appliance is running.
Check gas input to the appliance using a clocking gas
meter or alternatively a pressure gauge connected to the
outlet pressure tap.
Turn mechanical minimum adjustment screw
counter--clockwise to increase the gas flow to the desired
value.
Connect PWM input signal.

WARNING
Adjustments must be made by qualified persons only.
If the appliance manufacturer supplies checkout and/
or service and maintenance instructions carefully
follow them. If these instructions are not provided then
use the procedure outlined below.
NOTE: For adjustment of additional electrical minimum setting
and/or gas outlet pressure during ignition see
appropriate Product Handbook of ignition control.

Final checkout
After installation and any adjustment start the appliance and
observe a complete cycle to ensure that all burner
components function correctly.

Pressure tap
The gas control is provided with a pressure tap of 9 mm outer
diameter. at inlet and outlet side.
When checking the pressure undo the screw a half turn and
slip tube over nipple.
Ensure that screw is retightened after making test.

Maintenance and service


Under normal circumstances no maintenance or service is
required.
Screws on the valve that have been sealed must never be
removed.

Maximum outlet pressure adjustment (see page 4)


Disconnect pressure feedback connection (if applicable)
Start--up appliance in order to have gas input to burner and
make sure appliance is running at maximum heat demand.
Check gas input to the appliance using a clocking gas
meter or alternatively a pressure gauge connected to the
outlet pressure tap.
Remove cap screw from maximum pressure regulator to
expose pressure regulator adjustment screw.
Slowly turn pressure regulator adjustment screw with a
suitable screw driver until the burner pressure required is
recorded on the pressure gauge. Turn adjustment screw
clockwise to increase or counter--clockwise to decrease
gas flow to the burner.
Replace pressure regulator cap screw.
Connect pressure feedback connection (if applicable).

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EN2R--9025 0108R6--NE

CONSTRUCTION AND WORKING PRINCIPLES


integrated modulation function by loading an integrated
regulator diaphragm (N) with the required force through
applying the appropiate current (based on % PWM input)
which is determined in the electronic circuit that is connected
to the gas control.
When the 2nd coil is energized at heat demand, but a 0%
PWM input, the plunger is moved down and the servo valve
opens. At this moment working gas can flow to the supply
orifice (O). At the same moment the minimum rate gas can
flow through the servo valve (K) and the minimum rate
adjustment screw (D) directly to the outlet.
When now the PWM input (heat demand) rises, the current
rises, the load on the regulator (N) rises and the pressure of
working gas in the servo system is being built up. At a
certain point this pressure opens the main valve (B) and the
outlet pressure rises. Now the main valve is modulating and
the outlet pressure is controlled by the balance between
generated forceon the plunger and outlet pressure through
the regulator diaphragm. The higher the force becomes, the
higher the outlet pressure will be and vice versa.
The outlet pressure can be limited to a maximum value by
setting of the maximum servo pressure regulator (C). This
maximum regulator is parallel to the integrated modulating
regulator. This means that the lowest of both settings will
determine the actual outlet pressure.
When the 2nd coil (M) is de--energized, the servo valve closes
and the supply of minimum rate gas and working gas are
shutt off. The load of the regulator diaphragm is released, the
working gas can bleed to the outlet through the regulator
seat and the main valve closes.

The VK4105G gas control contains a first direct electric


ON/OFF safety valve (A) and a second ON/OFF and
modulating servo operated main valve (B).
The modulating valve maximum output pressure can be
limited by a maximum pressure regulator (C). The minimum
output can be adjusted by a throttle adjusment screw (D).
Description of the direct electric operator
The direct electric operator (RAC) is built up with a valve seat
that is machined in the die cast body (E), the coil plate assy
that forms the upper part of the product (F) and the plunger
assy as moving part (G).
A sleeve (H) guides the plunger assy (G) and is assembled
between body and coil plate assy. If the solenoid is energized
the plunger is pulled--in and moves upwards. So the safety
valve, which is directly attached to this plunger, is opened.
The impact of the plunger on the stop is damped by a rubber
silencer in the plunger.
Description of the servo operated modulating main valve
The main valve (B) is a spring closed and diaphragm (J)
actuated valve located in the main gas passageway between
the direct operated safety valve and the outlet of the gas
control .
The main valve is opened by the servo systems working gas
acting against the main valve diaphragm (J). So the position
of the main valve (B) is controlled by the working gas
pressure in the servo system.
The working gas is obtained from the main gas stream
through the servo valve (K) and a supply orifice.
The servo valve is located parallel to the main valve and is
oprerated by the 2nd coil (M). This 2nd coil also operates the

M
N

D
G

F
B
A

E
J

Fig. 12. Servo pressure regulation working

14

EN2R--9025 0108R6--NE

QUALITY ASSURANCE STATEMENT


Assembly processes are guided by work instructions.
Patrol inspections form part of the assembly processes.
At the end of the assembly phase, all gas controls are
leakage and performance tested/adjusted.
Assembly inspection is performed by employees of the quality
control department, using their own authorised equipment.
All inspections (incoming and assembly) are performed by
trained personel and according inspection procedures.

Products are manufactured under an ISO 9001 (1994) based


and certified Quality System.
The quality system is described in the Honeywell Combustion
Controls Center Quality Assurance Programme and its related
operational procedures and instructions.
The quality system is approved by Gastec against certificate
number 9.302/2.
The quality organisation is responsible for defining,
maintaining, improving and verification of the quality systems
in the field of design, production process and field quality
service.

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EN2R--9025 0108R6--NE

STANDARDS AND APPROVALS


Approvals
The gas control conforms with the following EC -- Directives:
Gas Appliance Directive (90/396/EEC)
Low Voltage Directive (73/23/EEC)
Electro Magnetic Compatability Directive (89/336/EEC)
The fact that the gas control is certified to European Standard
EN 88 EN 126 and EN161 means that the gas control meets
the requirements in all EC and EFTA countries.
Details per O.S. number can be found in the Approvals List.
The registration number specific for each O.S. number is
mentioned on the label of the control.

Standards:
The VK4105G has been designed to meet the European
Standards:
EN 88: Pressure govenors
EN 126: Multifunctional controls.
EN 161: Automatic shut off valves
The safety shut off valve meets class B requirements.
The servo operated main valve meets class J requirements.
A class J valve as mentioned in EN 161; 1997 is equal or
better than a class D valve as mentioned in EN 297 and
EN 483 and class D valves as mentined in other standards.
According to bending stresses the gas control meets the
highest requirements (group 2).
The pressure govenor meets class B performance.
Regarding electric safety, the gas control can be used in
appliances according to European Standard for household
electrical requirements EN 60335 series.
The gas control also meets all Electro Magnetic Compatability
standards for non--industrial appliances.

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EN2R--9025 0108R6--NE

ORDERING INFORMATION
When ordering specify:
Model number of CVI gas control component required: see
model number chart below.
The correct pilot burner for the installation concerned: refer
to Honeywell ignition products guide EN0R--0038.

NOTE: Complete gas control, replacement parts and


accessories will be available under
TRADELINE label. Ask your wholesaler for
details.
NOTE: An up--to--date product survey, with details of
all new and existing products in these series, is
available.
Contact your local Honeywell sales
representative for more information.

Ordering Specification number

VK 4 1 0 5 G 9999

VK: product family identifier

Specification number

4: line voltage

G: Integrated modulation with


maximum pressure regulation
H: Integrated modulation without
maximum pressure regulation

1: CVI system valve

5: No pilot outlet, DBI ignition system


Valve classification
0: Class B + J
Fig. 13. Model number chart VK4105G

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EN2R--9025 0108R6--NE

REPLACEMENT PARTS AND ACCESSORIES


Flange assemblies
Connection size

Configuration

O--ring
g

Screws

Packing
gq
quantity
y
(
(pcs)
)

Order number

Straight Elbow
3/
8
3/
8
3/
8
3/
8
1/
2

BSP.Pl

--

YES

YES

200

45.900.400--101

BSP.Pl1)

--

YES

YES

200

45.900.400--103

BSP.Pl1)

--

YES

NO

200

45.900.400--129

BSP.Pl2)

--

YES

YES

200

45.900.400--128

BSP.Pl

--

YES

YES

200

45.900.400--102

1/
2
1/
2
1/
2
1/
2
1/
2
1/
2
1/
2

BSP.Pl

--

NO

NO

200

45.900.400--106

BSP.Pl

--

YES

NO

200

45.900.400--131

BSP.Pl1)

--

YES

YES

200

45.900.400--104

BSP.Pl1)

--

NO

NO

200

45.900.400--108

BSP.Pl1)

--

YES

NO

200

45.900.400--130

NPT

--

YES

YES

200

45.900.400--122

--

YES

YES

200

45.900.400--132

--

YES

YES

200

45.900.400--123

NPT1)

18.4 mm
1)
2)

Not applicable for mounting over pilot outlet.


Applicable for mounting in all directions.

Home and Building Control


Combustion Controls Center Europe
Honeywell BV
Phileas Foggstraat 7
7821 AJ Emmen
The Netherlands
Tel: +31 (-- )591 695911
Fax: +31 (-- )591 695200
http://europe.hbc.honeywell.com

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EN2R--9025 0108R6--NE